Wooden pallet with end deck boards and butted spacers

ABSTRACT

A pallet includes a base layer and a cargo layer. The cargo layer includes a pair of spaced apart end deck boards, and intermediate deck boards between the pair of spaced apart end deck boards. Spacers are between the end deck boards and the intermediate deck boards. The spacers are positioned so that they butt up against the end deck boards to increase pallet durability. The spacers include block spacers, L-shaped metal brackets and U-shaped metal brackets. Spaced apart supports are coupled between the base and cargo layers and forming a gap therebetween for receiving a lifting member.

RELATED APPLICATION

This application claims the benefit of provisional application Ser. No. 62/702,433 filed Jul. 24, 2018, which is hereby incorporated herein in its entirety by reference.

TECHNICAL FIELD

The present disclosure relates to the field of pallets, and more particularly, to a wooden pallet having an improved resilience to impacts from material handling equipment.

BACKGROUND

Conventional wooden pallets include a base layer and a cargo layer separated by support blocks. The cargo layer traditionally has end deck boards assembled on connector boards that run the full length or width of the pallet. The end deck boards are nailed through the connector boards into the support blocks to build the primary structure of the pallet. The end deck boards are also known as lead boards. Intermediate deck boards are placed between the end deck boards.

To move the pallet with cargo thereon, forklift tines are inserted into the gaps between the base and cargo layers. If the forklift is not stopped in time, the forklift may crash into one of the end deck boards of the pallet. The end deck board may not be able to withstand such an impact over time. Accidents such as this weaken the pallet and greatly shorten the lifespan of the pallet, thereby causing the pallet to be repaired more frequently and/or removed from service long before its anticipated life cycle has been reached.

SUMMARY

A pallet includes a base layer, a cargo layer, and a plurality of spaced apart supports coupled between the base and cargo layers and forming a gap therebetween for receiving a lifting member.

The cargo layer includes a pair of spaced apart outer connector boards, and at least one center connector board between the pair of outer connector boards. A pair of spaced apart end deck boards is on the pair of outer connector boards and the at least one center connector board, with the end deck boards being orthogonal to the outer connector boards and the at least one center connector board. A pair of spaced apart intermediate deck boards is on the pair of connector boards and the at least one center connector board, with the intermediate deck boards adjacent a respective end deck board and orthogonal to the outer connector boards and the at least one center connector board. A plurality of spacers is coupled to the outer connector boards and the at least one center connector board, with an edge of each spacer butted against a respective end deck board.

The spaced apart supports coupled between the base and cargo layers include outer supports and center supports. The outer supports may be configured as a C-shaped bracket having an upper flange contacting one of the outer connector boards and a bottom flange contacting the base layer. The center supports may be configured as a circular-shaped cylinder having an upper surface contacting the at least one center connector board and a bottom surface contacting the base layer.

An opposing edge of each spacer may be butted against a respective intermediate deck board. Each spacer may be configured as a rectangular-shaped block, as a U-shaped bracket or as an L-shaped bracket. A width of each spacer may be less than a width of the outer connector boards and a width of the at least one center connector board.

The outer supports may comprise metal and the center supports may comprise plastic. The outer and center connector boards may comprise wood, and the end and intermediate deck boards may comprise wood.

The intermediate deck boards and the end deck boards may have a same width.

The cargo layer may further comprise at least one additional intermediate deck board between the pair of intermediate deck boards, with the at least one additional intermediate deck board being spaced from the pair of intermediate deck boards.

The base layer may comprise a pair of spaced apart bottom end deck boards, and at least one bottom center deck board between the pair of bottom end deck boards, and wherein the bottom flange of each outer support contacts one of the bottom end deck boards or the at least one bottom center deck board. The bottom end deck boards and the at least one bottom center deck board may be aligned with the end deck boards and the intermediate deck boards in the cargo layer.

Each circular-shaped cylinder may comprise a center hub with an opening extending therethrough, an outer wall, and a plurality of ribs extending between the center hub and the outer wall. The base and cargo layers may include fastener openings aligned with the openings in the center hubs in the center supports, and may further comprise a plurality of fasteners for coupling the base and cargo layers to the center supports. The plurality of ribs may be recessed from opposing ends of the center hub and the outer wall.

The upper flange in each outer support may include a single fastener opening extending therethrough, and the bottom flange in each outer support may include a pair of fastener openings extending therethrough. The base and cargo layers may include fastener openings aligned with the openings in the outer supports, and may further comprise a plurality of fasteners for securing the base and cargo layers to the outer supports.

Another aspect is directed to a method for making a pallet as described above.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view of a wooden pallet with butted block spacers for the end deck boards in accordance with the disclosure.

FIG. 2 is a top perspective view of the wooden pallet shown in FIG. 1 with one of the butted blocks spacers removed.

FIG. 3 is a bottom perspective view of the wooden pallet shown in FIG. 1.

FIG. 4 is a top view of the wooden pallet shown in FIG. 1.

FIG. 5 is an end view of the wooden pallet shown in FIG. 1.

FIG. 6 is a side view of the wooden pallet shown in FIG. 1.

FIG. 7 is a top perspective view of another embodiment of the wooden pallet shown in FIG. 2 with butted L-shaped bracket spacers.

FIG. 8 is a side view of the wooden pallet shown in FIG. 7.

FIG. 9 is a top perspective view of another embodiment of the wooden pallet shown in FIG. 2 with butted U-shaped bracket spacers.

FIG. 10 is a side view of the wooden pallet shown in FIG. 9.

FIG. 11 is a top perspective view of another embodiment of the wooden pallet with butted block spacers for the end deck boards in accordance with the disclosure.

FIG. 12 is a top perspective view of the wooden pallet shown in FIG. 11 with one of the butted blocks spacers removed.

FIG. 13 is a bottom perspective view of the wooden pallet shown in FIG. 11.

FIG. 14 is a top view of the wooden pallet shown in FIG. 11.

FIG. 15 is a side view of the wooden pallet shown in FIG. 11.

FIG. 16 is an end view of the wooden pallet shown in FIG. 11.

FIG. 17 is a perspective view of one of the metal bracket outer supports shown in FIG. 11.

FIG. 18 is a perspective view of one of the plastic cylinder center supports shown in FIG. 11.

FIG. 19 is a perspective view of a wooden block support as an alternative to the supports shown in FIG. 11.

FIG. 20 is a top perspective view of another embodiment of the wooden pallet shown in FIG. 12 with butted L-shaped bracket spacers.

FIG. 21 is a side view of the wooden pallet shown in FIG. 20.

FIG. 22 is a top perspective view of another embodiment of the wooden pallet shown in FIG. 12 with butted U-shaped bracket spacers.

FIG. 23 is a side view of the wooden pallet shown in FIG. 22.

DETAILED DESCRIPTION

The present description is made with reference to the accompanying drawings, in which exemplary embodiments are shown. However, many different embodiments may be used, and thus the description should not be construed as limited to the particular embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete. Like numbers refer to like elements throughout, and prime notations are used to indicate alternate embodiments.

Referring initially to FIGS. 1-6, the illustrated wooden pallet 10 includes a base layer 20, a cargo layer 30, and a plurality of wooden support blocks 40, 46 coupled between the base and cargo layers. The support blocks 40, 46 form a gap 50 between the base and cargo layers 20, 30 for receiving a lifting member, such as fork lift tines.

The cargo layer 30 includes a pair of spaced apart wooden end deck boards 32, and wooden intermediate deck boards 34, 35 between the end deck boards 32. Intermediate deck boards 34 are adjacent the end deck boards 32, and the intermediate deck board 35 is between the intermediate deck boards 34.

Block spacers 60 are positioned between the end deck boards 32 and the intermediate deck boards 34. In particular, the block spacers 60 are butted with both the end deck boards 32 and the intermediate deck boards 34. Alternatively, the block spacers 60 are butted with only the end deck boards 32. Pallet durability is significantly improved by having the end deck boards 32 butt up against the block spacers 60.

Also included within the cargo layer 30 are a pair of spaced apart wooden connector boards 36 and a wooden intermediate connector board 37. The connector boards 36 and the intermediate connector board 37 are orthogonal to the end deck boards 32 and the intermediate deck boards 34, 35. The end deck boards 32 and the intermediate deck boards 34, 35 are positioned on the connector boards 36 and the intermediate connector board 37.

The block spacers 60 are coupled to the connector boards 36 and the intermediate connector board 37 with nails 62. The illustrated block spacers 60 have a width less than a width of the connector boards 36 and the intermediate connector board 37. For the block spacers 60 on the connector boards 36, they are aligned with the outside edges of the end deck boards 32 and the intermediate deck boards 34. For the block spacers 60 on the intermediate connector board 37, they are centered on the intermediate connector board 37.

The illustrated positioning of the block spacers 60 is not to be limiting. Other positions by the block spacers 60 on the connector boards 36 and the intermediate connector board 37 may be used as long as the block spacers 60 butt up against the end deck boards 32.

In some embodiments, the block spacers 60 may not be positioned on each connector board 36 and each intermediate connector board 37. For example, the block spacers 60 may be on the connector boards 36 and not on the intermediate connector board 37. As another example, the block spacers 60 may be on the intermediate connector board 37 and not on the connector boards 36.

The width of the block spacers 60 may also vary. For example, the width of the block spacers 60 may be the same width as the connector boards 36 and intermediate connector board 37. As another example, a single block spacer 60 may extend between both connector boards 36 so that it also covers the intermediate connector board 37.

The block spacers 60 may be formed from a number of different materials. The material for the block spacers 60 may be wood, plastic or metal, for example.

The base layer 20 includes bottom deck boards 22, 26 orientated in the same direction as the end deck boards 32 and the intermediate deck boards 34, 35 in the cargo layer 30. The bottom deck boards 22, 26 are directly coupled to the support blocks 40, 46.

The illustrated support blocks include corner support blocks 40 and center support blocks 46 between the corner support blocks 40. The corner support blocks 40 and the center support blocks 46 each have a rectangular shape, and with the center support blocks 46 being orthogonal to the corner support blocks 40. A rectangular shape has unequal adjacent sides so that a length and width of a rectangular shaped corner support block 40 are not equal as in a square shaped corner support block.

The bottom deck boards 22, 26 include a pair of bottom end deck boards 22 and a bottom center deck board 26 between the pair of bottom end deck boards 22. A width of the bottom center deck board 26 is greater than a width of the bottom end deck boards 22.

In other embodiments, the corner support blocks 40 and the center support blocks 46 may have a square or circular shape. When the support blocks 40, 46 are the same size, then a width of the bottom center deck board 26 may be equal to a width of the bottom end deck boards 22.

In the illustrated wooden pallet 10, a size of each end deck board 32 and the intermediate deck boards 34 may have the same dimensions. For example, a width of the end deck board 32 and the intermediate deck board 34 may be 145 mm, for example. In another example, the width may be 78 mm.

In other embodiments, the size of each end deck board 32 and a corresponding intermediate deck board 34 have different dimensions. For example, the width of the end deck board 32 may be 98 mm and the width of the corresponding intermediate deck board 34 may be 75 mm, and vice-versa as yet another example.

Traditionally, there is a gap between the end deck boards and the adjacent intermediate deck boards. In the illustrated wooden pallet 10, pallet durability is significantly improved when block spacers 60 are butted up against the end deck boards 32.

The cargo layer 30 also includes at least one additional intermediate deck board 35 positioned between the intermediate deck boards 34. This additional intermediate deck board 35 is positioned so that there is a gap between the adjacent intermediate deck boards 34. The dimensions of the end deck boards 32 and the intermediate deck boards 34 as well as additional intermediate deck boards 35 positioned between the intermediate deck boards 34 are selected and spaced such that coverage of the cargo layer 30 is within a range of 70-85 percent of a maximum total surface area of the cargo layer 30 when there are no gaps between the boards.

A width of the intermediate deck board 35 may be the same as a width of the intermediate deck boards 34. Alternatively, in other embodiments, this intermediate deck board 35 may have a different width.

As noted above, the illustrated wooden pallet 10 also includes center support blocks 46 between the corner support blocks 40. When the support blocks 40, 46 are rectangular shaped, the center support blocks 46 may be positioned in a different orientation to the corner support blocks 40. In other words, the center support blocks 46 may be at a 90 degree angle to the corner support blocks 40. In other embodiments, orientation of the center support blocks 46 is the same as orientation of the corner support blocks 40.

Another feature of the illustrated wooden pallet 10 is the edges of each support block 40, 46 being angled or chamfered. The angled edges 42 may be within a range of about 25 to 75 degrees, for example, to deflect the impact force of the forklift tines should such an impact occur. The illustrated edges are angled at 45 degrees.

When the edges 42 of each corner support block 40 are angled, the corresponding outermost edges 38 of the end deck boards 32 are angled to match the angled edges 42 in the corner support blocks 40. The corresponding outermost edges 39 of the connector boards 36 in the cargo layer 30 are angled to also match the angled edges 42 in the corner support blocks 40. The corresponding outermost edges 28 of the deck boards 22 in the base layer 20 are also angled to match the angled edges 42 in the corner support blocks 40.

Referring now to FIGS. 7-8, the block spacers 60 may be replaced by L-shaped metal brackets 60′. A screw 62′ is used to secure each L-shaped metal bracket 60′ to either a connector board 36 or to an intermediate connector board 37. The L-shaped metal brackets 60′ butt up against the end deck boards 32. The L-shaped metal brackets 60′ do not contact the intermediate deck boards 34. Pallet durability is advantageously increased with the L-shaped metal brackets 60′.

Referring now to FIGS. 9-10, the block spacers 60 may be replaced by U-shaped metal brackets 60″. A screw 62″ is used to secure each U-shaped metal bracket 60″ to either a connector board 36 or to an intermediate connector board 37. The U-shaped metal brackets 60″ butt up against the end deck boards 32 and the intermediate deck boards 34. Pallet durability is advantageously increased with the U-shaped metal brackets 60″.

Another embodiment of the pallet 10 discussed above will now be discussed in reference to FIGS. 11-16. The illustrated wooden pallet 110 includes a base layer 120, a cargo layer 130, and a plurality of supports, 140, 146 coupled between the base and cargo layers. The supports 140, 146 form a gap 150 between the base and cargo layers 120, 130 for receiving a lifting member, such as fork lift tines.

The cargo layer 130 includes a pair of spaced apart wooden end deck boards 132, and wooden intermediate deck boards 134, 135 between the end deck boards 132. Intermediate deck boards 134 are adjacent the end deck boards 132, and the intermediate deck boards 135 are between the intermediate deck boards 134.

Block spacers 160 are positioned between the end deck boards 132 and the intermediate deck boards 134. In particular, the block spacers 160 are butted with both the end deck boards 132 and the intermediate deck boards 134. Alternatively, the block spacers 160 are butted with only the end deck boards 132. Pallet durability is significantly improved by having the end deck boards 132 butt up against the block spacers 160.

Also included within the cargo layer 130 are a pair of spaced apart wooden connector boards 136 and a wooden intermediate connector board 137. The connector boards 136 and the intermediate connector board 137 are orthogonal to the end deck boards 132 and the intermediate deck boards 134, 135. The end deck boards 132 and the intermediate deck boards 134, 135 are positioned on the connector boards 136 and the intermediate connector board 137.

The block spacers 160 are coupled to the connector boards 136 and the intermediate connector board 137 with nails 162. The illustrated block spacers 160 have a width less than a width of the connector boards 136 and the intermediate connector board 137. For the block spacers 160 on the connector boards 136, they are aligned with the outside edges of the end deck boards 132 and the intermediate deck boards 134. For the block spacers 160 on the intermediate connector board 137, they are centered on the intermediate connector board 137.

The illustrated positioning of the block spacers 160 is not to be limiting. Other positions by the block spacers 160 on the connector boards 136 and the intermediate connector board 137 may be used as long as the block spacers 160 butt up against the end deck boards 132.

In some embodiments, the block spacers 160 may not be positioned on each connector board 136 and each intermediate connector board 137. For example, the block spacers 160 may be on the connector boards 136 and not on the intermediate connector board 137. As another example, the block spacers 160 may be on the intermediate connector board 137 and not on the connector boards 136.

The width of the connector blocks 160 may also vary. For example, the width of the connector blocks 160 may be the same width as the connector boards 136 and intermediate connector board 137. As another example, a single connector block 160 may extend between both connector boards 136 so that it also covers the intermediate connector board 137.

The block spacers 160 may be formed from a number of different materials. The material for the block spacers 160 may be wood, plastic or metal, for example.

The base layer 120 includes bottom deck boards 122, 126 orientated in the same direction as the end deck boards 132 and the intermediate deck boards 134, 135 in the cargo layer 130. The bottom deck boards 122, 126 are directly coupled to the supports 140, 146.

The supports include outer supports 140 and center supports 146 between the outer supports 140. The outer supports 140 are configured as metal brackets having a U-shape as illustrated in FIG. 17. The center supports 146 are configured as circular shaped plastic cylinders as illustrated in FIG. 18.

Bolts 163 are used to secure the supports 140, 146 to the corresponding boards in the base and cargo layers 120, 130. A single respective bolt 163 is used for each support 140, 146 when securing to the cargo layer 130. For the base layer 120, a pair of respective bolts 163 is used for each outer support 140 and a single respective bolt 163 is used for each center support 146 when securing to the base layer 120.

For the metal bracket outer supports 140, a single bolt opening 170 is in the cargo layer facing side, and a pair of bolt openings 172 is in the base layer facing side. For the plastic cylinder center supports 146, a single bolt opening 180 is in the cargo and base layer facing sides. The plastic cylinder center support 146 includes a center hub 190 that includes the bolt openings 180, and ribs 192 radially extending from the center hub 190 to an outer wall 194. Notches or openings 195 are provided at the opposing ends 147, 149 to drain any liquids that may get inside of the plastic cylinder center support 146.

As an alternative to the metal bracket outer supports 140 and the plastic cylinder center support 146, wooden block supports 101 may be used as illustrated in FIG. 19. In other embodiments, wooden block supports 101 may be used to replace the outer supports 140 while the center supports 146 remain, or may be used to replace the center supports 146 while the outer supports 140 remain.

Nails 166 are used to couple adjacent boards together in the cargo layer 130. The nails 166 are used to secure the end deck boards 132, the intermediate deck boards 134 and additional intermediate deck boards 135 to the connector boards 136 and the intermediate connector board 137. The nails 166 may be clinched nails.

The edges of each wooden support 101 may be angled or chamfered. The angled edges 102 may be within a range of about 25 to 75 degrees, for example, to deflect the impact force of the forklift tines should such an impact occur. The illustrated edges are angled at 45 degrees.

In the illustrated wooden pallet 110, a size of each end deck board 132 and a corresponding intermediate deck board 134 butted thereagainst have the same dimensions. For example, a width of the end deck board 132 and the intermediate deck board 134 butted thereagainst may be 145 mm, for example. In another example, the width may be 78 mm.

In other embodiments, the size of each end deck board 132 and a corresponding intermediate deck board 134 have different dimensions. For example, the width of the end deck board 132 may be 78 mm and the width of the corresponding intermediate deck board 134 may be 98 mm.

Traditionally, there is a gap between the end deck boards and the adjacent intermediate deck boards. In the illustrated wooden pallet 110, pallet durability is significantly improved when block spacers 160 are butted up against the end deck boards 132.

The cargo layer 130 also includes at least one additional intermediate deck board 135 positioned between the intermediate deck boards 134. The additional intermediate deck boards 135 are positioned so that there is a gap between the adjacent intermediate deck boards 134. The dimensions of the end deck boards 132 and the intermediate deck boards 134 as well as additional intermediate deck boards 135 positioned between the intermediate deck boards 134 are selected and spaced such that coverage of the cargo layer 130 is within a range of 70-85 percent of a maximum total surface area of the cargo layer 130 when there are no gaps between the boards.

A width of the intermediate deck boards 135 may be the same as a width of the intermediate deck boards 134. Alternatively, in other embodiments, the intermediate deck boards 135 may have different widths. In addition, the boards making up the intermediate deck boards 135 may have different widths. For example, one of the intermediate deck boards 135 may have a width of 98 mm and another one of the intermediate deck boards 135 may have a width of 78 mm.

Referring now to FIGS. 20-21, the block spacers 160 may be replaced by L-shaped metal brackets 160′. A screw 162′ is used to secure each L-shaped metal bracket 160′ to either a connector board 136 or to an intermediate connector board 137. The L-shaped metal brackets 160′ butt up against the end deck boards 132. The L-shaped metal brackets 160′ do not contact the intermediate deck boards 134. Pallet durability is advantageously increased with the L-shaped metal brackets 160′.

Referring now to FIGS. 22-23, the block spacers 160 may be replaced by U-shaped metal brackets 160″. A screw 162″ is used to secure each U-shaped metal bracket 160″ to either a connector board 136 or to an intermediate connector board 137. The U-shaped metal brackets 160″ butt up against the end deck boards 132 and the intermediate deck boards 134. Pallet durability is advantageously increased with the U-shaped metal brackets 160″.

Another aspect is directed to making a pallet 110 as described above. The method includes providing a base layer 120, and providing a cargo layer 130. The cargo layer 130 includes a pair of spaced apart outer connector boards 136, and at least one center connector board 137 between the pair of outer connector boards 136. A pair of spaced apart end deck boards 132 is on the pair of outer connector boards 136 and the at least one center connector board 137, with the end deck boards 132 being orthogonal to the outer connector boards 136 and the at least one center connector board 137. A pair of spaced apart intermediate deck boards 134 is on the pair of connector boards 136 and the at least one center connector board 137, with the intermediate deck boards 134 adjacent a respective end deck board 132 and orthogonal to the outer connector boards 136 and the at least one center connector board 137. A plurality of spacers 160 is coupled to the outer connector boards 136 and the at least one center connector board 137, with an edge of each spacer 160 butted against a respective end deck board 132.

The method further comprises coupling a plurality of spaced apart supports 140, 146 between the base and cargo layers and forming a gap therebetween for receiving a lifting member. The supports may comprise outer supports 140 configured as a C-shaped bracket having an upper flange 141 contacting one of the outer connector boards 132 and a bottom flange 143 contacting the base layer 120, and center supports 146 configured as a circular-shaped cylinder having an upper surface 147 contacting the at least one center connector board 137 and a bottom surface 149 contacting the base layer 120.

Many modifications and other embodiments of the invention will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the invention is not to be limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included within the scope of the appended claims. 

That which is claimed:
 1. A pallet comprising: a base layer; a cargo layer comprising a pair of spaced apart outer connector boards, at least one center connector board between said pair of outer connector boards, a pair of spaced apart end deck boards on said pair of outer connector boards and said at least one center connector board, with said end deck boards being orthogonal to said outer connector boards and said at least one center connector board, and a pair of spaced apart intermediate deck boards on said pair of connector boards and said at least one center connector board, with said intermediate deck boards adjacent a respective end deck board and orthogonal to said outer connector boards and said at least one center connector board; a plurality of spacers coupled to said outer connector boards and said at least one center connector board, with an edge of each spacer butted against a respective end deck board; and a plurality of spaced apart supports coupled between said base and cargo layers and forming a gap therebetween for receiving a lifting member, and comprising: outer supports configured as a C-shaped bracket having an upper flange contacting one of said outer connector boards and a bottom flange contacting said base layer, and center supports configured as a circular-shaped cylinder having an upper surface contacting said at least one center connector board and a bottom surface contacting said base layer.
 2. The pallet according to claim 1 wherein an opposing edge of each spacer is butted against a respective intermediate deck board.
 3. The pallet according to claim 2 wherein each spacer is configured as a rectangular-shaped block.
 4. The pallet according to claim 2 wherein each spacer is configured as a U-shaped bracket.
 5. The pallet according to claim 1 wherein each spacer is configured as an L-shaped bracket.
 6. The pallet according to claim 1 wherein a width of each spacer is less than a width of said outer connector boards and a width of said at least one center connector board.
 7. The pallet according to claim 1 wherein said outer supports comprise metal and said center supports comprise plastic.
 8. The pallet according to claim 1 wherein said outer and center connector boards comprise wood, and wherein said end and intermediate deck boards comprise wood.
 9. The pallet according to claim 1 wherein said intermediate deck boards and said end deck boards have a same width.
 10. The pallet according to claim 1 wherein said cargo layer further comprises at least one additional intermediate deck board between said pair of intermediate deck boards, with said at least one additional intermediate deck board being spaced from said pair of intermediate deck boards.
 11. The pallet according to claim 1 wherein said base layer comprises a pair of spaced apart bottom end deck boards, and at least one bottom center deck board between said pair of bottom end deck boards, and wherein the bottom flange of each outer support contacts one of said bottom end deck boards or said at least one bottom center deck board.
 12. The pallet according to claim 11 wherein said bottom end deck boards and said at least one bottom center deck board are aligned with said end deck boards and said intermediate deck boards in said cargo layer.
 13. The pallet according to claim 1 wherein each circular-shaped cylinder comprises a center hub with an opening extending therethrough, an outer wall, and a plurality of ribs extending between said center hub and said outer wall.
 14. The pallet according to claim 13 wherein said base and cargo layers include fastener openings aligned the openings in the center hubs in said center supports, and further comprising a plurality of fasteners for coupling said base and cargo layers to said center supports.
 15. The pallet according to claim 13 wherein said plurality of ribs are recessed from opposing ends of the center hub and the outer wall.
 16. The pallet according to claim 1 wherein the upper flange in each outer support includes a single fastener opening extending therethrough, and the bottom flange in each outer support includes a pair of fastener openings extending therethrough; and said base and cargo layers include fastener openings aligned the openings in said outer supports, and further comprising a plurality of fasteners for securing said base and cargo layers to said outer supports.
 17. A method for making a pallet comprising: providing a base layer; providing a cargo layer comprising a pair of spaced apart outer connector boards, at least one center connector board between said pair of outer connector boards, a pair of spaced apart end deck boards on said pair of outer connector boards and said at least one center connector board, with said end deck boards being orthogonal to said outer connector boards and said at least one center connector board, and a pair of spaced apart intermediate deck boards on said pair of connector boards and said at least one center connector board, with said intermediate deck boards adjacent a respective end deck board and orthogonal to said outer connector boards and said at least one center connector board; a plurality of spacers coupled to said outer connector boards and said at least one center connector board, with an edge of each spacer butted against a respective end deck board; and coupling a plurality of spaced apart supports between said base and cargo layers and forming a gap therebetween for receiving a lifting member, with the supports comprising: outer supports configured as a C-shaped bracket having an upper flange contacting one of said outer connector boards and a bottom flange contacting said base layer, and center supports configured as a circular-shaped cylinder having an upper surface contacting said at least one center connector board and a bottom surface contacting said base layer.
 18. The method according to claim 17 wherein an opposing edge of each spacer is butted against a respective intermediate deck board.
 19. The method according to claim 18 wherein each spacer is configured as a rectangular-shaped block.
 20. The method according to claim 18 wherein each spacer is configured as a U-shaped bracket.
 21. The method according to claim 17 wherein each spacer is configured as an L-shaped bracket.
 22. The method according to claim 17 wherein a width of each spacer is less than a width of said outer connector boards and a width of said at least one center connector board.
 23. The method according to claim 17 wherein each circular-shaped cylinder comprises a center hub with an opening extending therethrough, an outer wall, and a plurality of ribs extending between the center hub and the outer wall.
 24. The method according to claim 25 wherein the plurality of ribs are recessed from opposing ends of the center hub and the outer wall. 